Sealing jaw for heat sealable film with zippered section
BACKGROUND OF THE INVENTION 
     The present invention relates to improvements in apparatus and methods for forming reclosable plastic bags, and more particularly to an improved method and mechanism for forming edge seams on adjacent bags which are cut to separate the bags. 
     In the manufacture of plastic bags, one form of manufacture employs material that is sealed by the application of heat and pressure opposed overlaid sheets of plastic from the front and back walls of a bag with a reclosable interlocking rib and groove plastic zipper along the top. Such sheets are continuous and separate bags are formed by sealing jaws which apply heat and pressure at the edges of the bag and cut the continuous length of film to separate adjacent bags. 
     In one well known form of the manufacture which is frequently referred to as a form, fill and seal process, thermoplastic material is fed forwardly and wrapped over a filling tube. At the edges of the plastic material, is an interlocking zipper. The material is fed downwardly over the filling tube and contents are dropped through the tube to fill individual bags. Individual bags are cut from the continuous length by heated sealing jaws being pressed at bag intervals and the resultant seam is cut intermediate its sides to separate individual bags which have seams running along their sides. As a seam is formed and the finished bag is cut, the contents are dropped into the bag and it is pulled downwardly whereupon a new seam is formed above the contents. Examples of this type of bag manufacture are illustrated in U.S. Pat. Nos. 4,709,533, Ausnit, and 4,617,683, Christoff and Ausnit. This arrangement of bag manufacture employs relatively high speed operation with the tubular material being incrementally pulled down over the filling tube and cut and cross-sealed. The integrity of the seam formed by the cross-seal depends upon the amount of heat transmitted to the plastic. It is essential that a complete integral seal be formed by supplying sufficient heat to the plastic to cause the overlaid sheets to melt at the seam edge but the heat must not be at a level so that melt holes are formed adjacent the seam in the bag plastic. Yet, the heat which is transmitted to the plastic must be sufficient to cause complete sealing. Difficulties are encountered in high speed operation varying from incomplete joining of the layers to form the seam to openings inadvertently caused in the plastic by the heated sealing jaws. 
     It is accordingly an object of the present invention to provide an improved method and apparatus for cross-seaming plastic bags such as in a form, fill and seal operation wherein the seams are of improved integrity and strength. 
     A further object of the present invention is to provide an improved cross-seaming apparatus and method for the formation of edge seams for bags wherein an improved appearing seam is formed and one which eliminates perforations and insures a more secure seam. 
     A further object of the invention is to provide an improved seaming apparatus and method wherein variances can be accommodated in the speed of seaming and operation without adversely affecting the integrity of the seams which are formed. 
     Another further object of the invention is to provide a cross-seaming apparatus and method for forming side seams in bags wherein a thicker amount of plastic occurs at the top of the bag due to the presence of an interlocking rib and groove fastener and wherein the seaming apparatus and method accommodates this thicker plastic without adversely affecting the integrity of the seam. 
     FEATURES OF THE INVENTION 
     A continuous length of plastic sheeting is drawn forward with the sheets overlaid to form front and side walls of a bag with the confronting faces of the sheets at the top of the bag having interlocking rib and groove zipper fasteners. At bag width intervals, sealing jaws are brought together to join the layers and the sealing jaws form parallel seams for the two adjacent bags with a knife cutting the plastic sheeting between the seams. To form secure seams, the sealing jaws are heated and preferably the face of the sealing jaws has a series of short ridges extending at right angles away from the knife at the center of the sealing jaw. Outwardly of the short ridges are elongate parallel ridges which diminish in height away from the edge of the seam. In accordance with the method and apparatus, the sealing jaws are non-parallel diverging away from each other from the seam edge and in one form, this divergence is accomplished by ridges of decreasing height. 
     Other objects, advantages and features of the invention will become more apparent with the teaching of the principles of the invention in connection with the disclosure of the preferred embodiments of the invention in the specification, claims and drawings in which: 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of seaming jaws about to be clamped together to form the side seam of a continuous bag extending between the jaws such as in the delivery end of a form, fill and seal machine; 
     FIG. 2 is an enlarged vertical sectional view taken substantially along line II--II of FIG. 1; 
     FIG. 3 is a sectional view taken substantially along line III--III of FIG. 2 and illustrating the appearance of the face of one of the sealing jaws; 
     FIG. 4 is an enlarged fragmentary sectional view taken substantially along line IV--IV for illustrating the relative height of the ridges on one of the sealing jaws; and 
     FIG. 5 is a sectional view taken substantially along line V--V of FIG. 4. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in FIG. 1, a tubular length of thermoplastic 10 is shaped to form a continuous bag with layers of plastic doubled at 13 to form the base of the bag and thereby provide front and back walls 10a and 10b of a completed bag. At the top 12, the layers are separated to form pull flanges for separating interlocking plastic rib and groove profiles 11. 
     In a form, fill and seal machine, the length of plastic tubing 10 will be fed downwardly or longitudinally and contents will be dropped into the interior of the tube. Spaced lateral cross-seals will then be formed laterally of the longitudinal axis by applying a clamping pressure across the bag and cutting a length from the tube to separate a finished bag. 
     The seam forming clamping pressure is provided by jaw members 14 and 15 which are arranged to reciprocate and to move together or apart slidable on horizontal rods 16 and 17. This movement is at right angles to the longitudinal axis along which the tubing is advanced and also at right angles to the lateral cross seals. The jaw assemblies have sealing and cutting jaw faces 18 and 19 which are moved against the overlaid layers 10a and 10b of plastic to form adjacent elongate seals. 
     With reference to FIG. 2, opposed jaw faces 20 and 22 move together to form a seam 26. Opposed jaw faces 21 and 23 move together to form a seam 27 on an adjacent bag. Elongate knives 24 and 25 are located between the jaw areas 20 and 21 for knife 24 and 22 and 23 for knife 25. These knives cut between seams 26 and 27 formed at the sides of the bag with the bags separated at a cut 27a. Thus, the seam 26 will form one edge of a bag 35 while seam 27 forms one edge of a bag 36. If FIG. 2 is viewed as a sectional elevational view, the bag tube can be descending off the forming tube and the lower bag 36 will have been completed and filled with contents and cut off of the length of tubular film. The bag 35 will form the next succeeding bag and contents will be dropped into the interior. The jaw assemblies 14 and 15 will be moved upwardly and then again clamped together to form another pair of side seams for adjacent bags and cut a finished bag from the chain. Suitable power operating mechanisms are provided to move the jaw assemblies 14 and 15 together to form the seams and to again separate them when a new length of bag is fed down between the jaws. 
     A unique feature of the invention provides seams for the bags wherein the seam is more firmly formed at the bag edge 35a and 36a and inwardly of the edge at 35b and 36b. This is accomplished by applying a higher sealing pressure at the edge of the bag which sealing pressure diminishes in an inward direction. 
     The higher sealing pressure at the bag edge will insure that the edges are completely joined, and the amount of heat transfer from the heated jaws is a function of the unit pressure applied to the plastic sheets. In other words, the plastic between the sheets will melt more thoroughly when more heat is applied, such as is accomplished by a higher seaming pressure than with the application of less heat as is accomplished by less pressure inwardly of the seam edge. 
     The structural arrangement shown in FIG. 2 preferably utilizes two opposed jaw assemblies of the same construction. However, it is envisioned that one jaw assembly may merely provide a support while the other jaw assembly will have the detail shown. The support and jaw or the two jaws function the same which is to apply more pressure and greater heat transfer at the edge of the seam than inwardly therefrom. With the transmission of less heat inwardly, the chance of the plastic melting and forming air leak perforations is reduced. 
     Another feature of the arrangement which forms a more firm seam at the outer edge of the bag is that this arrangement particularly accommodates the extra bulky plastic which occurs at the location of the interlocked profiles 11. As the jaws move together, the two overlaid layers at the side edge of the bag are of uniform thickness except at the location of the profiles. The jaw arrangement which reduces the pressure inwardly accommodates the flow of extra plastic at the location of the profiles without danger of leakage occurring due to breakaway or perforation of the plastic. Also, as the seaming jaws move together, the extra plastic at the profiles which becomes molten must flow away to escape. With the jaws shaped to recede away from each other inwardly of the seam, they accommodate this extra flow of plastic resulting from the profiles. 
     The application of a higher sealing pressure adjacent the edge of the seam, which sealing pressure diminishes inwardly toward the center of the bag, can be accomplished with various structures and in a preferred form, as shown in FIGS. 2 through 5, ridges or ribs are formed in the faces of the sealing jaws. In FIG. 2, the jaw 18 shown on the left has an upper jaw portion 20 and a lower jaw portion 21. The jaw portion 20 is opposed by the jaw portion 22 on the opposite jaw, and the jaw portion 21 is opposed by the jaw portion 23 on the opposite jaw. The upper jaw portions form the elongate seam for a bag 35 and the lower jaw portions form an elongate seam for the edge of a bag 36. The bags are severed by the knives 24 and 25 cutting the bags apart at 27a. 
     The firmest edge seam junctures are formed at the bag edges 35a and 36a diminishing inwardly toward the inner edges of the seams at 35b and 36b. 
     As shown in FIG. 3, the jaws are formed with ridges 28 which extend at right angles to the edge of the bag and at right angles to the knives 24 and 25. These ridges are short and are at the extreme edge of the jaw. Further inwardly on the seam are elongate ridges 30 which extend parallel to the elongate seam. These ridges are shown in FIG. 4 spaced apart a distance 35. The ridges are shown at 31a, 31b, 31c and 31d. The innermost ridge 31a is the highest. Moving outwardly, the next ridge 31c is lower and the next ridge 31d is still lower. The height of the ridge 31a is shown by the dimension 32. The ridge 31c is lower by a dimension 33 than the ridge 31b. The outermost ridge 31d is lower by a dimension 34 than the ridge 31b. Thus, it will be seen that moving inwardly from the edge of the seam, the ridges are of diminishing height. The ridges have sloping sides of a convenient angle such as 45° as shown by the angles 37. 
     In operation, the jaws are brought together to form the two elongate seams on adjacent bags at the same time. The very edge of the seams are formed by the ridges 29 and the portion of the seam further inwardly from the edge of the bag is formed by the ridges 30 and 31 which extend parallel to the seam. The ridges 30 and 31 are lower than the ridges 28 and 29. Also, progressing outwardly, the ridges 30 and 31 are of diminishing height. 
     With this structure, the jaws apply a pressure which diminishes inwardly from the outer edge of the bag and the effective sealing surface of the jaw is non-parallel to the opposite jaw so as to apply a tapered penetration pressure to the seam. The outer edge of the seams are pressed more firmly together and the seam is squeezed with a tapered penetration pressure. Also, heat transmission is transmitted to the seam more intensively at the outer edge and diminishes inwardly. 
     This receding dimension of the heat sealing surface of the jaws accommodates the flow of extra plastic at the profiles 11 insuring that the profiles will not be destroyed and will be in a condition to be immediately interlocked toward the very edge of the bag, that is, to the edges of the seam. 
     In operation, opposed front and back overlaid layers of a bag are brought between seaming jaw assemblies 18 and 19. The jaw assemblies are brought together and maximum sealing pressure is applied by the innermost ridges 28 and 29, FIG. 3. Lesser pressure is applied moving inward from the edge of the seam by the parallel ridges 30 and 31 with the ridges being of diminishing height as shown in FIG. 4. This allows for the distribution of the extra plastic between the profiles and insures a valid safe seal at the edge of the bags.